Installation

Timing Chains

ALLDATA Editor Note: Volkswagen does not provide a step by step timing chain removal procedure. The procedure depicted below is for the BJS engine, the BDF is similar.


Installing the oil pump timing chain and the chain tensioner with tensioning rail:





- First, rotate the crankshaft to TDC for cylinder 1. When doing this, the ground tooth on the crankshaft drive gear -arrow- must align with the main bearing cap joint.

- Turn the intermediate shaft so that the flattened side faces up.

- Install the timing chain into the guide rail and mount in onto the crankshaft.





- Install the large sprocket into the timing chain so that the tab on the sprocket aligns with the tab in the cylinder block -B-.

- Mount the large sprocket and the chain onto the intermediate shaft.

During installation make sure that the chain runs completely straight in the guide rail from the crankshaft to the intermediate shaft.

• The ground tooth on the crankshaft drive gear must align with the main bearing cap joint -arrow A-.
• The tab on the large sprocket must align with the tab -arrow B behind it.





- Mount the small sprocket on the intermediate shaft. Installation is possible in one position only.

- Install and tighten the bolt -arrow- hand tight because the small sprocket must be removed one more time.





- Install the chain tensioner with tensioning rail. To do this, release the locking splines on the chain tensioner with a small screwdriver and press the tensioning rail against the tensioner.

Note: If equipped with a transportation safeguard, remove this immediately after installation.





- Install the chain tensioner with tensioning rail in this position and tighten the bolts -arrow- to 8 Nm.

Installing the camshaft timing chain:

Conditions

• The camshaft adjusters are installed
• The camshaft lobes -A- for cylinder 1 must face each other.





- Install the camshaft bar -T10068 A- into both camshaft grooves.





- Remove the sprocket bolt -arrow- and small sprocket. The large sprocket may not be removed.

- Guide the camshaft timing chain from above, between the tensioning rail and the guide rail in the direction of the intermediate shaft.

Note: The 3 adjacent copper colored chain links are placed on the small sprocket.
• It is possible that an additional copper colored chain link os equipped on a new camshaft timing chain. Ignore this chain link.





- Rotate the camshaft adjuster all the way to the left until it stops. Lay the camshaft timing chain onto the guide rail and onto the camshaft adjuster. Align the 2 separate copper colored chain links -C- to the marks on the camshaft adjusters.

- Install the small sprocket into the camshaft timing chain. The mark -B- must align with the center copper color chain link -A-.





- Tighten the sprocket bolt -arrow- to 60 Nm + an additional 90° (1/4) turn. The additional turn can occur in several stages.





Note: When turning the crankshaft, the tensioning rail must be pressed strongly by hand (instead of the chain tensioner) against the camshaft chain -arrow- to prevent the chain from jumping off.





Check the position of the crankshaft relative to the intermediate shaft.
• The ground tooth on the crankshaft drive gear must align with the main bearing cap joint -arrow A-.
• The tab on the large sprocket -arrow B- must align with the tab behind it.





Check the position of the copper colored chain links with respect to the adjustment marks:
• Align the copper colored chain links to the adjustment marks:





- Check the adjustment marks on the camshaft adjuster with the marks on the control housing.

- The marks -A and B- on the camshaft adjusters must align with the notches -arrows- on the control housing -C-.





- Forcefully press the camshaft tensioning rail by hand (instead of with the chain tensioner) against the camshaft timing chain and rotate the crankshaft 4 turns in engine rotation direction.

Note: After rotating the crankshaft, the copper colored chain links are no longer aligned with the adjustment marks.

The assembly may continue if all the adjustment marks fit.





- Clean the old sealant from the 3 mm holes in the cylinder head gasket -arrows-

Note: With the cylinder head installed only half the holes in the cylinder head gasket are visible.

- Clean the sealing surfaces on the engine and both covers; they must be free of oil and grease.

- Check whether the sealing flange pins are inserted in the cylinder block.





- Thinly coat the sealing surfaces -shown cross hatched- of the sealing flange with silicone adhesive sealant -D 176 501 A1-.

Note: The lower sealing flange must be installed within 5 minutes of applying sealant.





- Install the sealing flange underneath -arrow- and tighten the bolts diagonally and in stages.





- Fill the 3mm holes in the cylinder head gasket -arrows- with the silicone adhesive sealant -D 176 501 A1-.

- Replace the seal in the sealing flange if there are any leaks.





- Check whether the alignment sleeves -2 and 3- are inserted in the cover.

- Insert the new seal -1- and new seal -4-.

- Coat the sealing surfaces on the cover with silicone adhesive sealant -D 176 501 A1 and install the cover immediately.





- Install the cover and lightly tighten all of the bolts. Then tighten the bolts as follows:
• Tighten the bolts -1 and 3- to 5 NM.
• Tighten the bolts -3- to 23 Nm.
• Tighten the bolts -1 and 2- to 10 Nm.

- Install the chain tensioner and tighten it to 40 Nm.

- Install thermostat housing.

- Install the cylinder head cover and intake manifold. Service and Repair

Tightening Specifications
Guide rail pin (without a collar) to cylinder block 10 Nm
Chain tensioner with tensioning rail to cylinder block 8 Nm
Sprocket to intermediate shaft 60 Nm + 90°
Sealing flange to cylinder block 10 Nm
Cover M6 10 Nm
Cover M8 23 Nm
Chain tensioner to cylinder block 40 Nm